Production of silicon-containing resins



STA-T PRODUCTION No Drawing;

sThea-invention relates to the production of silicon containing resins.

I iItis known-that silicon-containing substances can-be used to produce synthetic materials have ingcured characteristics superior in many re-.- spectsjto, those of other synthetic materials. Recognized'shortcomings of synthetic materials derived from silicon-containing substances are their relatively slow cure rates and high cost. It has ,beensuggested that cured materials having many of the superior characteristics of those producedfrom silicon-containing substances but without theirslow eure rates and high cost can be produced by modifying an alkydresin with a siloxane. obtained by; hydrolysis of a silane.

Alkyd-resins aregavailable commercially, usually; as solutions in such solvents as xylene (sol-v vents not more volatile than xylene are ordinarily;

2,607,755 I M F SILICON-CONTAINING if Raymond H. Bunnell, Toledo, Ohi0,assignr to l Libbey-Owens-Ford Glass- Company, Toledo, .j Ohio, acorporation of Ohio r I Application December 4,1948, 7' g Serial-No. 63,697 a 1 thetic resins are produced by a method that com};

- prises 'hydrolyzing an'organosilane in a' hydrolyz preferable). It is known "that silanes are not conveniently hydrolyzed in such solvents as xylene because there is a great likelihood of the formation of a water emulsion which can ;be brokenonly with comparative dimculty. Silanes are readily hydrolyzed in such solvents as diethyl ether, without complications; therefore, the nat ural way to prepare a siloxane solution with which tomodify'an alkyd is to hydrolyze the silane as a solution in diethyl ether, mix the purifled hydrolyzed solution with the final solvent e.; g. xylene), distill the ether, and mix the remai ing siloxanesolution with the alkyd. This method ;has been suggested, and has been used to produce resins -that yield cured materials having many of the desirable characteristics of both silicones. and alkyds.- v a r It has beenfound, however, that silicone-modifid 'alkyds preparedas described in the preceding para IaPhlack the uniformly high quality essential ,to a commercial product in that the curedn'iaterial frequently shows a haziness which be used to produce cured materials of uniformly: high'quality that are freefrom haziness can be preparedby a simplemethod.

" In the practice of the present invention syning solution and1inthe-p-resence of an organic solvent, adding a solution of the hydrolyzed product comprising the organic solvent to -an alkyd resin, and heating the resulting mixture] I-t'has beendiscovered that the haziness commonly found in siliconemodified alkyds heretoforeproduoed can be" eliminated by. hydrolyzing the organosilane in the presence of an organic solvent and then combining the hydrolyzed product and-thealkydwithout first distilling off all of ;such solvent; FIfh'ew-solvenbmay be distilled after' thecornbination' of the alkyd with the sil oxane, or the solvent may be ofsuch a character that it can be allowed to remain in the final product.

Synthetic resins are produced in the practice of the invention. by mixing an organic solvent; solution of the products of hydrolysis of a silane with an' alkyd resin, andheating the, resulting; mixture. o The. silane that is? hydrolyzed can be as'inglesilane or a mixture, ofsilanes, Qrgano e;

.silanes that can be, used in theflpractice oi the invention-consistof a silicon atom to-;whic h are attached four -monovalent'; radicals, not 1;-nr1 o1 ethan twoof which are organic radicals such as primary or secondary alkyl radicals, aralkyl'radi cals; aryl radicals or; alkaryl radicals each; having'from l-top12 carbon atoms, the remainder of said monovalentradicals being hydrolyzable. radicals.1p,A primary --or. secondary alkyl radical; attached to the silicon atom'can be methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, secondary; butylor any primary or secondaryalkyl radical havingyfrom 5; to 12 carbon atom's." When the alkylradical-is methyl the procedure by which the hydrolysis products are combined with the alkydresin should be conducted carefully in order toavoid gellingthe mixture before compatibility is achieved. It has been suggested that gelling, can be avoided by usingbutanol as the s olvent and gradually raising the temperature flof the mixture to about 190 0., thencoolingand adding more butanol andgradually raising. the tern:- perature of the-mixture to about 225 C. Ifthe reactants are mixed and heated under reflux for: about one hour using xylene as the solvent the mixture gels to a worthless mass. It is significant that ethyl does not'actl like a homologue of methyl in this respect, as is demonstrated byv the example hereinafter given. An aralkylra dical attachedto tne snmdn atom can b'a benzy l, hen th h a l h et r membrane radical. An aryl radical attached to the silicon alkoxy, amino, aroxy and acyloxy; The halo radical is any one having an atomic weight less than 80 (i. e., fiuoro, chloroorrbromo). The

alkoxy radical is any primary or secondary 2.1:

tyl) -trich1oro-, methylchlorodifiuoro-, methylfiuorodich1oro-, dimethylfluorochloro-, diethyldiethoxy-, ethyltrimethoxyor ethoxyor propoxyor n-butoxyor isopropoxy-, monohydrotrichloroor bromoor fluoro-, dihydrodich1oro-, monohydmmethyldichlorm, monohydroethyldich1oro,-,-;v monohyd-rophenyldichloro-, triy met yb d insthy c om-j lrdihyd odimethyl-, diethylchloroethoxy-, ethylchlorodiethoxy-,' n-propylchlorodifluoro-, n-propylfluorodichloro isopropylchlorodifiuoro-, iso- *propylfluorodichloro-, n-butylch1orodifiuoro-, nbritylfluorodichlorm, isopentyltrichloro-, ethylkoxy radical having from one to four carbon atoms (i. e., methoxy, ethoxy propoxy, isopro: poxy, n-butoxy, isobutoxy, or secondary butoxy). Amino is simply the --NH2 group. Aroxy radicals are any in which the aryl group isphenyl, or a mono-, dior tri-substituted phenyl radical, each substituent being a primary, secondary .or' tertiary alkyl radical having fromoneto fiveJcarbon'atoms, the totalnumber of carbon atoms in the side chains being not more than five (i. e., the aryl radical is phenyl, or ortho-, :meta-or para-methyl phenyl, any dior tri-methylphenyl,

or any substituted. phenyl in which the substituents are: one ethyl; one ethyl and onemethyl; two ethyls; two methyls and one ethyl; twoethyls and one methyl; either propyl radical; either propyl radical and methyl; either propyl radical and twomethyls; either propyl radical and-ethyl; any butyl-radical; any butyl radical and methyl; or any pentyl radical). The acyloxyradicalhas the general formula w r a t I V O 7 ll z-c-oin which Z is a saturated or unsaturated straight,

- yltriethoxymethyldichloro.-, methylpropyldichloro-, n-butylmethyldichloro-, I n hexylmethyldichloro methor n-butoxy-, a methyloctyldich1oro-,, dimethyldiethoxyor n-butoxy-, di-

jznethylchloro-n-butoxy, n-propyltriethoxy-, isopropyltriethoXy-, n-butyltriethoxy-, chloromethoxyethoxy-, isopentyltriethoxy-, ethyldiethoxyacetoxy-, phenyltrifluoroor ethoxyor propoxy or 'isobutoxye,:. diphenyldifiuoro or chloroor bromoor ethoxyo'nephenoxye; ethyl phenyldichloro-, phenylmethyldiethoxw, ethylbenzyldichloro-', 1 diphenylchlorophenoxy-; henylbenzyldiethoxy-,- benzyltriethoxy-; (2,4- dimeth ylphenyl) triethoxye, alpha naphthyltriethoxye, beta-naphthyltriethoxy-silanes and-the like;=-

Organosilanes thatconsist of-asil-icon atom to which are attached four monovalent radicals g-not mor than two of which are primany or secondbranched or closed chain hydrocarbon radical having from one to eighteenscarbon atoms, or phenyl or substituted phenyl ithe. substituents,

I if any, consistingof-from one to three -alkylradi-t cals each having from one to five carbon atoms; and all having a total ofnot more than fiveiicarbon atoms, as hereinbeforedescribed; i .J

Silan'es that can be :used in thepractice of the invention also include those having 1101731110166 than two-hydrogens attachedto the siliconvatom inthesilane molecule. Hydrogen acts as either a; hydrolyzableor an organic radicaLdependin upon the particular hydrolyzing solution that is .used. For example, if the hydrolyzing solution is a-dilute water solution ofa'mineral acidgof water alone, hydrogen isnot hydrolyzed, andacts as an organic radical; on the other h'and,'.'if-thehydrolyzing solution is a dilute water'solution of a base, hydrogen is-hydrolyzed, so that it acts as a'hydrolyzabl'e radical; Thus-whethef-hydrogen is countedas a hydrolyzable radical or asan organic radical (e. g., in computing the r/Si ratio; as hereinafter described) depends upon what hydrolyzing solution is employed.

Examples of silanes that can be to produce products used to modify valkyd resins in the practice of the invention include methyltrifluoroor chloroor bromo-, dimethyldifluoroor chloroor bromo-, ethyltrifluoro or chloro-, diethyldich1oro-, n-propyltrifluoroe or chloro-, di-n-propyldichloro, isopropyltrifiuoro nbutyltrifiuoroor chloro-, di-n-butyldifluoro-, isobutyltrichloro-', secondary V butyltrichloro n-- pentyltrifiuoroor ch1oro-, di-n-pentyldifluoro 2 L-- methylpentyltrichloro-, 3(2,2,4-trimethylpenhydrolyzed ary alkyl radicals, aralkyl-radicals, aryl radicals or alkaryl-radicals and have a from I :to -zgear qn atoms; the remainder of such 'monova'lenb rad icals being hydrol-yzable radicalsg=ar -prepared by means of a Gr-i'g'na'rd' reaction'betwe n-ii "a silicon tetrahalide, an' alky1'--orthosilicat organotrihalosilane or' an organotrialkoxysilane and' (2) a halo-substituted-hydrocarbonFin' tl'ie presence of magnesium;- the halo-substituted hydrocarbon and the magnesium arebel-iiied-to react to produce an organo magnesiurn -halide which then reacts with'-- the silicon tetrahalide, alkylorthosil-icate' organotrihalosilaneor-organo trialkoxysilane. Such reactions-prOceed -at-I a faster rate at elevatedtemperatures and are usually exothermic-in nature. -It is ordinarily-desk; able, therefore, to conduct the reactionin a vessel equipped with a hea-ting coiland-cooling means (e. g; a reflux condenser-) ;so that thefreactants can be heated-to such a;-temperaturethatthe reaction proceeds ata substantial rate; and-then the maximum output of -heat generated by the reaction ca-n be re moved through; the cooling means. It is usually-desirable ,tqbohdfitth reaction in the presence of diethyl ether-as '"s ol' vent; the ether has; the double efiectof initiating the Grignard' reaction and orjfabuiapiiigbom trol of the temperature in the-reaction vessel. The reaction proceeds less readily-to produce alk oxysilanes than it does--to iproduce ha-losila ne s so that-it may be desirabletq conduct the "reaction between an, organo magnesiumhalide and an alkyl orthosilicate under somewhat more drastic conditions than are usually desirable' when the reaction is conductedwitha tetranalo v silane. This is particularlytrue when the 'reac? n is Used, o duc tdi koxysilane tr in an alkyl orthosilicate; in this case,it "may' be s slirable to initiate the reaction in 'th presencej" of diethyl etherand thenvto supply; sufiicient; heat to the reactor so that 'all the'ether 'is distilled. The reaction is then conductediataisuificientiy high temperature that two alkoxyi radical are replaced by organo-radicals -Tlfl'iernagne um isobutyl- V salts produced-during the course of the reaction are removed by filtration, and the organosilanes are isolated by fractional distillation of the filtrate Th silanes so produced-have hydrolyzable groups'which are halo radicals or alkoxyradicals. Silanes having, attached to the silicon: atom in the silane molecule, one or more amino-radicals are produced by reaction between ammonia and an appropriate silane having one ormore halo radicals attached to'the silicon atom. By such a reaction halo is replaced by NHz; organosilanes containing amino groups as hydrolyzable radicals can be produced by such a reaction.

silanes having hydrolyzable radicals which consist of acyloxy groups are produced by reaction "between an acid anhydride and the appropriate silane having hydrolyzable radicals which con- 'all the alkyl substituents contain a total of not more than five carbon atoms as hereinbefore described. j

As the foregoing discussion indicates, silanes having hydrolyzable radicals which consist of halo or alkoxy groups are prepared directly from a silicon tetrahalide or from analkyl orthosilicate, while silanes havinghydrolyzable radicals which consist of amino, acyloxyor aroxy groups are prepared as secondary products, i.-e., by reacting the product of one of the first reactions in order to change the hydrolyzable radicals. As

a consequence, silanes having hydrolyzable radicals which consist of halo or alkoxy groupsare less expensively prepared when a Grignardreaction is used to produce the silanes than are those having hydrolyzable radicals which consist oi amino, acyloxy or aroxy groups and are, ordinarily, preferred. This is particularly true because the hydrolyzable radicals are removed from the silane molecule by the hydrolysis reaction so that they do not form a part of the siliconcontaining resin produced in the practice of the invention. However, all hydrolyzable radicals .donot undergo hydrolysis at the same rate the mostv readily hydrolyzed being halo. Amino, acyl oxy, alkoxy and aroxy are more diflicult to hydrolyze than is halo, alkoxy and aroxy being the most diflicult, and in instances where rate of hydrolysis .is of particular importance, it may be preferred to use a'more expensive silane having hydrolyzable radicals that. are amino, acyloxy or aroxy. 7

silanes (that can be used in the practice of the invention) having hydrolyzable radic'alsthat are halo groups are also produced by,means of a reaction between an alkene or an arylalkene having from 2 to 12 carbon atoms and a-silane whose molecule consists of a silicon atom to which are attached (a) from one to two hydrogens; (b) from two to three halogens; and (c) not more than one radical that is alkyl, aralkyl, aryl or alkaryl and has not more than 12 carbon atoms. Such a reactioniprovides a particularly desirable method for producingsilanes'to be used in the practice of the invention because it is well adapted to, being conducted'continuously, using inexpensive starting materials; Itds be- '7 Examples of 'alkenes' that can be reacted with ilieved' that this reaction canbe used to produce certain organohalosilanes inexpensively and in large quantities; consequently, organosilanes having hydrolyzable radicals, that are halo groups are the most desirable starting materials for use in the practice of the invention. ;,Si1anes that areproduced by means of such reaction have alkyl radicals derived from alkenes by the addition of a hydrogen to one of the carbon atoms linked-by the double bond in the alkene molecule, or aralkyl radicals 'so derived from the aryl alkene, the free valence being attached to the other of the carbon atoms linked by the double bond in the alkene or aryl alkene. Such. alkyl for aralkyl radicals have from 2 to 12 carbon atoms; the alkyl radicals may be straight :or branched chains, whereas the aralkyl radical may be a phenylethyl, naphthylethyl, phenylpropyl or (alkylphenyl) ethyl radical. silanesmhaving such alkyl or aralkyl radicals are also preferred starting materials, the most desirable ones hav-' ing alkyl radicals derived from the most readily available and inexpensive alken'eafor example, ethylene. i

Examples of the halo-substituted hydrocarbons that can be reacted'with a silicon tetra- -halide, an alkyl orthosilicate, an org'anotrihalosilane or an organotrialkoxysilane, in the presence of magnesium, as hereinbefore described, include primary and secondary alkyl halides,

' ;such as methyl bromide or chloride or iodide,

ethyl bromide or chloride, n-propyl bromide-or chloride, isopropyl bromide or chloride, n-butyl bromide or chloride, secondary butyl bromide or chloride, isobutyl bromide or ch1oride,:n-amyl bromide, isoamyl bromide, secondary amyl bromide, n-hexyl bromide, n-heptyl bromide, 3- bromoheptane, 4-bromoheptane, n-octyl bromide, 2-bromooctane, 2-iodononane, l-bromo-3- methylnonane, 4 chloro 4 methylnonane, 5- chloro-5-methylnonane, 2-bromodecane, l-bromo-fi-methyldecane, 2-chloro-2-methyldec'a'ne, 5chloro-5-ethyldecane, l-bromododecane and 4- bromododecane; halo derivatives of'hydrocarbons of the benzene series, such as bromobenzene alpha-bromotoluene, alpha-iodotoluena-obromotoluene, m-bromo-toluene, p-bromotoluene, 4-bromo-o-xylene, 4-bromo-m-xylene, 5- bromo-m-xylene, 2-bromo-p-xylene, 3-bromopseudocumene, 5-bromopseudocumene', fi-br'omopseudocumene, 2-bromomesitylene, 3-bromo-oxylene, Z-bromol-ethyl benzene, 4-bromo' l-ethyl benzene, 4-bromo-l, 3-diethyl benzene, 2-iodo- 1, 3, 5-triethyl benzene, 6 -bromo-3-ethyl toluene, 2-bromo-4-ethyl toluene, 4-bromo-1-propyl benzene, 4-bromo-isopropyl benzene, 4-bromo-lmethyl-3-isopropyl benzene, -fi-bromo-l methyl- 3 isopropyl benzene, 2 bromo p cymene, 3--bromo-p-cymene, 4-bromo-1-butyl benzene,

4-bromo-l-tertiary butyl benzene, 4-bromolisoamyl benzene and 4-bromo-1-tertiary amyl benzene; and halo derivatives of hydrocarbons of the naphthalene series, such as alpha -bro inonaphthalene, beta-bromonaphthalene, l bromo- B-methyl naphthalene, l-bromo-Y-methyl naphthalene, l-bromo-2-methyl naphthalene, 4-bromo-2-methyl naphthalene, 8-bromo-2-methyl naphthalene, 1-bromo-5-methyl naphthalene,

l-bromo-2, 7-dimethyl naphthalene, 4-bromo-1, G-dimethyl naphthalene, 1-bromo- 2,6-dimethyl naphthalene, 4-bromo-l,2-dimethyl naphthalene, l-bromo-2,3-dimethyl naphthalene, 1-bromo-4- methyl naphthalene and 7-br0r'no-1-methyl naphthalene.

a sushi; i iiibse moieeuie eonsists ofa silicon atom w icn are attached-la)" fromrson'eyto two'shyogensy (b) ffo'in twoto l threeshalogens; gand not' more than-{ one radical that isaalkyl "a'ralliy'l, aryl or alkar'yl and has not imore than v 12' 'earbon atoms} as hereinbef ore idescr iloed, 1nclude' -thyl'e'ne; propene; and any .butene; .pen- *tene, -=-hex 'ene, -heptene,= ectene, nonen'e, 'decene, unlieceneor dodecenei St3 rene;-'a11y1:benzene, 3-

r Iyl toluene and alpha -iviny1naphthalenei are amples of "aryl alkenes that can bei so reacted. slams: are l hydrolyzed-in the ap'ractice" of the invention by means of ea two phase' "hydrolysis resents-.2 It may be possible to conduct such i hydr'olysis reaction by adding thesilanezor silene mixture to a hydrolyzing xsolution: or ito zautwo- "phase-mixture of "an" organic solvent :and :a hydrolyzingeisolution Y (the: hydroly'zing TSO111tl01l";-'iS

usually "water; but tmay be, occasionally, va zwater solution; of i "a base, Ior a dilute water solution of an inorganic acid') orvl bya'ddingfthe solution -or 'fliwo-ph'ases'mixture to the silane," but it'ris ordinarily: preferable that thesilane' or'si1aneI mixture be dissolved in an organic solventiandthat -thiszisilane,solution be added to a :iihydrolyz'ing solution, or that: the 1 hydrolyzing solution" the adde'di'to the silane solutiom. The organic I :solvent thatis rusedman'zbe one boiling :(atatmosphericipressurel as :liigh as about 200% Cgibut -it"'-ise usually; preferable to use 'oneiboilingiznot,

.higher'thantabout'lfiii" C., and most desirable" to use one' boiling notzhigher th'anaboutt 130? C.

i "The solvent that is t usedi should -betonelthatiis 'tnot 'substantiallyjsoluble in- Water: and thatzis isufiicientlyL-high boiling so; thatit'i's IlOtzidiStiHBd duringthe hydrolysis reactionyi'. e:,i'should boil,

-(at atmosphericpressurel at a temperature not substantially lowertthanto CsExam'plesnf the solvents that cam-be eu'sed v include? hydromcarbon solvents "such .as-benzene,-. to1u'ene,"=?xy-, 40 len'es, hexanes; :heptanes, and zoctanesy and others such as diethyl; ethylpropylspdipropyls and =propylbutyls. :Highex'; aliphatio'valohols tgwhich -arelnotx substantially? soluble in water) .such;as,nbutanol, the pentanols and the he):- ,anols'm'ay makeup E'FmiIIOIYpOI'tiOn ('i. 'ej not nore than about 10 Weight per cent) I of the solevent. As has been stated'hereinbefore, hydrolysis oo f-silanes in xylene solution is difficult because sof theuformation of an emulsion; however','-this emulsion canbe broken (e. g; by heating) and tl e hydrolysis products so obtained canbe uniiggedf, with 'alkyds in the practice ofwthe' inven- ,tion. f-BCCBJISB-hYdI'OlYSlS proceeds 'mor'e rea'diIy .nwenthesi1anes are dissolved imethrscilvents, iwithoutisuch complications 1 as the formation of emulsions, it isausually; preferable to I use a di- -alk yl ether havingfrom 4 170.6 carbon atoms as thesolvent forthe silanes. The most-desirable V solyent is; dieth yl, ;ether 5=Ethylmethyl ether-can also b a used,but'is usually notrcommercially practicable because; of its low'boiling point.--A

solyent, isconsidered to be notisubstantially I soluble in yvater' if it is soluble to anaextentjnot ezficedingabout grams per- 100 cc; of Water at aboutIf1C, 1

Most desirably the "semesters hydrolyzed 'by adding the silane solution to the' hydrolyzing "s'bliitiontslowly' (i. eQuSuallyJat-such a rate that one 'mol of silanes is iadded in not less thanabout 5minutes'faltho'u'gh'; insonie instances, a slightly f a ster"rate of addition can be used; it is ordi- 'lnarily 'pre erab1e that the silane s be added at *siicli a'ratethat one mole'isaddedrin not less d-rol :addon; otherwise, vlocal overheating may rei tin.-,=sp t n a s qtwlmtet p s le e add ;Ihe hydrolyzing solution that is used should gqolnprise at least about one mol .of waterlfor EVEIYJQWQ equivalents 'of hydrolyzable radicals to he hydrolyzed and;.maycomprise a substantial excess e. g., i a:S -Inuchfas about lfl mols of water T to eyery -two 'equiyalents, oflhydrolyz able radi- N ls, but it iswus ually} preferable that the hidrdly zing" solution ,comp'ris iirjom -aboiiti25 to abdut mols 16f; watenfor every two equivalents 20 ito b lhydrolyzed'. When; the, hydrolYzihg'SOl'ution is a dilute Water solution "of an'ii'n acid theinorganic acid 'canb'e'any "mineral acid. siichlasjhydroohloric;phosphoric or sulfuric; hy- Qd'r clilori'cv .usiially' beingpreferred. ex-

elyidilut fsolution isusually preferred, e. g.. one containing" 'fonlyfa few drops of about one normal ,acid'per' mol'bf' water; although one that fisaslmucn as about oneehalf normal maybeused nie instances. f When the hydrolyzin'g {soluv30 ti'oii isa dilute water solution of a base; it :is

1 g st desirable because of its availability 357a t ih te f "do .w f nib 1 i" i ei b fii e i nitO *th 'ase in thefhydrolyzin'g solution-"shouldbe i- 'Ihefamount i he'organic solyentthat-isbresfent during the: -h yolrlfysis-- reactionmay vary 'v ithin widelimits, depending upon various oilf- :cuir ilstances, such as the solub ility of th'e 'soIVent finat'er; the 'per" cent of -s'olids desired in the 5 finish'ed' alkyd silicone; and the rate at- 'vvhioh the sil'a-rie is hydrolyzed. f Usually; it is desirable that f-t-he volume *of: the "solvent used 'be at least about e'qual to'one half the-volume of the silanes liein'g hydrolyzed, and. it' -may' be advantageous "t hat-the volume oi -solvent be 'as "much as ten -ti ines thef volume of the-silanes :bein'g hydrolyze'dF It isusua l bi eferableg however; that volumeoftlie solvent be at -le'ast about qual to' the volume 'of 'the :silanes; andnot greater 1 than about five times the volume of the silan'esr- A large:volume-ofsolvent tends' to re- -tardthe rate of -hydrolysis fso that-an easily 5 hydrolyzed silanei mays advantageously i: be? "1 hyl Cdrolyze'di with ai'larger volume: of solvent .cth'an' is desirable with .a 5 more: diflicultly hydrolyzabl'e silane. Afterxan torganosilane has been hydrolyzed; as

hereinbe'foresclescrihedga silanediolican." be'added e s ennae si-ee tde iabifi aeo'mss 1 herein to indicate the total number of nonhydrolyzable radicals attached to silicon atoms in the molecules of the silanes divided by the total number of silicon atoms.) It is usually-de-r sirable that the r/Si' ratio be at least about 0.6, and: preferable that it be at least about 0.8. Ordibe not greater than about 1.3. The organosilane that is hydrolyzed, as hereinbefore described.

can be a single silane or a mixture of two or:

more silanes. No silane used in the practice of the invention has an r/Si ratio higher than,2.0; sothisis the maximum possible r/Si ratio. It has been found that resins having satisfactory characteristics for many uses can be produced by modifying an alkyd resin with the products of the hydrolysis of a single silane having an r/Si ratio of 2.0, e. g., diphenyldichlorosilane. but it is usually preferable to produce a some-'- what faster curing resin having greater cured hardness by using a mixture of silanes having a'lower r/Si ratio within the range hereinbefore set forth. A lower r/Si ratio can be achieved by using a mixture of-silanes, some of which-have an r/Si ratio of 2.0 and some of which have an r/Si ratio of 1.0; in some instances it may be advantageous to modify the silane mixture further by, incorporating therein a tetrafunctional silane such as asilicon tetrahalide, e. g,

silicon tetrachloride, silicon tetrabromide orsilicon tetrafiuoride, or an alkyl orthosilicate in which the alkyl radical is a primary or secondary alkyl radical having from one to four carbon atom s, e.--'g., ethyl orthosilicate. Such modification is required when itis desired to achieve an r/Si ratio'lower than 1.0.; a v

j A; solution of the'hydrolyzed product comprising'the organic solvent (-i. e., arsolution of the products of hydrolysis of-the organosilane which includes at least a'substantial portion of the organic solvent in which the organosilane is dissolved prior' to hydrolysis) is added to an alkyd resin, and the resulting mixture is heated, in the practice of the-invention. As has been hereinbefore stated, the organosilane is hydrolyzedby means of a two-phase hydrolysis reaction; When thejhydrolysis is considered to be complete, the

two layers (i. e.,- the water layer and the silane layer)-are separated; because-the two layers are not. completely immiscible, it is usually desirable towash' the silane layer with'water,'-icombine the washings with thewaterlayer and then extract the combined water-layer and washings with an organic solvent, usually, for convenience, thev solvent in which the organosilane was "dissolved prior .to hydrolysis, although'any solvent that is substantially water insoluble and volatile (as these terms are hereinbefore'defined) can be used. This extract is, then "combined with the silane layer, and the mixture constitutes a-solution 'of the hydrolyzed product comprising an organic solvent.; It'is usually desirable'that this solution be dried, e. g., over anhydrous calcium chloride or sodium sulfate, before it is mixed with the alkyd resin, and it maybeadvantageous to add other materials, such as the desired amount of a solvent other than that in which the silane is dissolved prior to hydrolysis (usually one higher boiling than that solvent) or a material thatmodifies the characteristics of the finished resin.

prior to; hydrolysis; e. g, diethyl ether, can 'be distilled after the solutionis dried and before it is mixed with the alkyd resin. For example, as

much as about one-third of the diethyl ether can be distilled from the dried solution of hydrolysis products prepared as described in the first pa a-V graph of the example given below; when the rest of the example is carried out as described it is I found that a resin indistinguishable from that produced by the procedureset forth in the ex-.

ample results. Apparently, however, suchdistil lation of a part of the hydrolysis solvent .before the solution is added to the alkyd resin increases the tendency of the finished resin to produce hazy films, so that it is usually preferred not to distil any of the hydrolysis solvent untilafter the solue-l tion of hydrolysis products has been added to the alkyd resin. In any event, it is desirable that'the amount of this solvent distilled beforethe solution is mixed with the alkyd be small enoughso that the amount remaining (in whichthe hy, drolysis products are dissolved) is notless. than about one-half of the volume of the'silan'es be-' fore hydrolysis, and preferable that it .be'such;

resins. -It is usually preferred to use a commervcial alkyd resin because of the cost advantage... The basic reactants from which a commercial;

alkyd resin is produced are glycerol and an arcmatic dicarboxylic acid. The aromatic dicarbox ylic acid can be phthalic acid, iso-phthalic acid, terephthalic acid, naphthalic-acid or a mono di-, trior tetra-chloroor alkyl-substituted phthalic acid, eachalkyl substituent being pri-, mary, secondary, or tertiary, and having from one 1 to five carbon atoms. sirable to use phthalic acid Lasthe aromaticdi .v carboxylic'acid, because-it is the most readily. available and the least expensiv of the acids that are availablein a pure form. When itis desired to produce a resin that is comparatively inexpen-f sive, color being not of critical importance, it may 1 be preferable to use abietic acid, usually in the form of dry-distilled rosin, in addition to the aro-- matic dicarboxylic .acid. Further, if'a, fiamere sistant resin is desired, one of the chloro-substituted phthalic acids may be advantageous. In addition, at least one fatty acid is usually reacted to produce the alkyd resin, by adding it to the glyceroland the aromatic dicarboxylic acid and then reacting, by reacting the glycerol and the fatty acid and then adding the aromatic d-icarg;

boxylic acid and reacting further, or by reacting the glycerol and the aromatic dicarboxylic and then adding the fatty acid and reacting further; Examples of the fatty acids that are used' to produce alkyds include capric, lauric, myristic, pal mitic, stearic, palmitoleic, oleic, linoleic, 1inolenic;-. elaeostearic, ricinoleic, and erucic acids.- Commercial alkyds are available having an excess of hydroxyl groups (over the total carboxyl groups" commerically as their glycerol esters, whicli a re' oils" derived from natural sources; examples of I the 0118 that provide sources for the fatty acids" Ordinarily, it is niQstdeirirjal tirle} "oili ioal m kernel oil; babassu=- oil,

seed oil; olive oil, neanut oil, sesame oil, corn oil, cottonseedgoil Sbybean oilisunflou rer-oil; Walnut oil nseed; oil; perillaoil; caster oil,' tung oil;

il', vvhale"oil andmenhadenoih Beef I, N nd- 1ard;: sardine ;and herring oils" also containgfattyacids Usually; the oil itself is; edltoh 'r act b m x tqppr d i he t cid oracidsg r c 7 ilnleenera anca d r n i Produced by a reaction that involves two OH groups, OilBlOf' which is ,ith'e hydroxy radical of an: alcohol (the al.- cohol, asindicated herein; is usually polyhydric) and the, 'otherfof .which. is .in a carboxylic; acid ra calgcfommercially useful alk yds are derived: 1 .fcqmpqsitionscomprising an excess of from a out. ate abo t 1 per: c o H ro p deg-2 rived from; "alcohols over 1 OH Qgroups derived.

' fromfcarboxylicfacids: This excess; is j nsed'n mrder tojjobtain an alkyd' resin having-a comparatively low acid number withoutthe necessity foiijanfinduly protracted reaction timeorthe V use "of amodifyingagent such; as aniline or "tolui I with a' hig h'acid number may also be unsuited-for usefiwith nitrocellulose; (Acid anhydridesi are; h'ereinl considered to have, thei samenumber "of" carbogrylic OH groups. per moleculefas the cor responding acidzl Itis usually desirable that the ratio of OH groups; derived from the aromatic diq'arboggylic acid', the fattyacid and the glycerol? tofto talOI-I'groups. in the composition; that, is re? d toproducethealkydresirrbe at leastabout substantially less than. 'nine tenthaof the" reacting groups are derived I from; the aromatic dicarboxylic acid, the fatty acid and the" h e t e l reei r st cs o fsh -r s ar lih'elyjtolbeinipairedf. Ordinarily, :it is preferable that ithejratio of groups derived f om; the arbmatic"dicarbpxylic acid,,theffatty' acid and tlfi glycerol'to total QI-L groups in the composition c than 'aronratic dicarboxylic acids areu'sedtQ Pro: d ice an alh'yd, or alcohols foth'er than glycerol; the purpose is tomodifyi specif c; characteristics I ofthe; resin this; modification; however; should beaccomplishedwithout impairing: other, desir-.

able characteristics "of the resin. It'is, to avoid, impairment of other desirable characteristics pr; 1 l ha i h j o 5 QH' o n mt derived from the {aromatic dicarboxylic 1 acid," the fa'bt ty acid and the glycerol is;us ually not; greater, tHan'ab uVlfiOO t: t A v r :Afiy dicarboxylic acid-can be used, .inlth'e. prepe ar'a'tion olf'the alkyd resin,..;in place of part of; ree -aromas dicarboxylic acid-,; and "any, "poly; hydric alcohol can be usedinplace of j part of t the ag1yeero1; The amount of such modifying agents used should be within the range-herein: beforaindicated, l The glycols whose use-as 'niodi fiers'risnsually' preferred include J ethylene glycol; propylene glycol, dipropyleneiglycol', any-butylene glycol-,- any -;polymethylene glycol in; th'i seriesfrorn trimethylene glycol,to,decylenezglycol 1(e.g.;i decamethylene glycol) or. any'polyethylene glycol ingthee series from.diethyleneglycol to, nona-V. ethylene glycol the acids whose useas modifiers, isi usually preferred include 1itaconic,citraconi rmaleic fumaric; on mesaconic acid;- any j normal acid Qin the series;froxn-..oxalic.'andimalonic to."

outr97 :lQOgand 'most desirable that: j

12" sebacic,- any cyclohexane' 'dicarboxylic 'acid;:.rorri, diglycolic; dilactic or resorcinol diacetic acidlg Modified alkyd resins can also beproduced using monocarboxylic' aromatic acids such-as hbenzoic:

' acid, monocarboxylic aliphatic acids having com acid, afatty' acid and the desired modifying in' gredient's'in the proportions:hereinbefore de scribed, and heating: the resulting reaction mix ture to altempera'turebetweenabouti20il" 'Ci'and about 250C. lt isfdesirable thati thislheatin -v be carried out in an inert atmosphera-e g.,"of'

nitrogen-or carbon dioxide; andlthe-inert gas can conveniently be bubbledthrough the reaction" mixture to effect stirring. .7 The material is main tained at a temperaturebetween about "200 and about 250' C.,' until the acid' number and the viscosity of the resin are-within the desired range; usually for a-time not shorter than about 4 hours and not longer than about 18 hours. The jalkyd resins are usually reacted fo'r -a'time sufficiently long that the acid numberis not higher than 10,

-diluted to the desired -p'er cent- 0f solids with'ea' hydrocarbon solvent; frequently xylene, toluene; 5 a petroleum solvent (e; g; .Var'nole'nefi a frac l tion' obtained incthe distillation of petroleum, boiling between" 310: ahdAlO? 1?; which con sists substantially of high boilingaliphatichydrm carbons) ,loran aliphatic hydrocarbon such" as a h'e itane,lor'.=an :octa'nel Other solvehtsffor ex' ample" higher alcohols of the aliphati'c" series (e;lf'g.;. .butanols and higher). or: higher boiling.

. ether's? (ei. g.) dibutyl? ethers, propyl butyl ethers and higher): can be used, but it "is usually preferredithat :the solvlent be a simple hydrocarbon; Mostccommercial's alkyds have from about 50' to about. 65 :weight: per ce'nt solids, but the .al'kyds can b'el'dilutedz-by addingxadditional solvent; or a.non=commercial alkyd'may be used having-anydesir'edesolids contentzultv. is ordinarily economicall y' preferable" that f the: alkyd contain: from. about: 40;."to about 65;; weight per cent solids; although :n'lOIflillltaSOllitiOIlS can be used; more concentrated 1' alkyds: .are; not: commercially" feasible; and; using more-dilute. alkyds ordinarily requires distillationiof. an unreasonable amount of solvent. duringitheheating. of thelresin after? mixing-with thehydrolysis:products.

When the. hydrolysis productsoi the-silane are mixed with the alkyd resin, the resulting'mixtureis heated: It .isbeliev'edIthat the resinxr'nixture is :partially; condensed during this heating; the formationgof Water: being evidence of such condensatior'r; 7 Usually, it. is :desirabletodistill the- Water; formed; duringeethel'sheating} it is convenient to;acc'omplishthis 'byeffecting the hat i ingzunder refluxireturning :to the resin mixture' thev materialthatzboilsi substantially above 0;:

It is waste han sets teats-a tea er matter h r than. .w t rjdfi ne' he. hea i (when the hydrolysis solventlis diethyl etherthe other volatile matter isthediethyl ethe'nandthis d stillednalon with the water while thejmaterial boiling "substantially above i09 o. i -re; A fluxed). However, when the hydrolysis is con ducted in asolvent that is to be present in the finished material, e. gl, .xylen e, and ndsubs-tantial excess o r-solvent isfpresentfiit is usually desirable thatithere be from about 50 to about-.70

weight, per cent solids in the finished resin; prefmethod embodyinglth invention will have about thedesired amount of's-olvents. Alternatively, an alkyd resin produced, specifically for use with silane hydrolysis products may be used, or the desired amount of a solvent or'solventmixtur'e may be added to the mixture of alkyd resin and silane hydrolysis products :before the-mixture is heated. I,

1' Exam-pZe;-- U v synthetic resinis produced by a procedure that comprises' hydrolyzin'g.Tarrorganosilane in a hydrolyzing solution and in the presence of an organic solvent, addinga vsolutioniof the hydrolyzed product 'coinp'rising'the organic solvent to an alkyd resin, and heating the resulting mixture according tothe following method;

An organosilane .(500 gramsof ethyltr ichlo rosilane) is mixed-with diethylether-(ZOOO cc.) and the resulting solution is poured .slowlyover -a stirred slurry of cracked ice and water (about 1000 grams of Water and 1000 grams of ice), the addition of the silane solution being complete in about minutes. As soon as the addition is complete the ether layer is separated from the water layer (in a separatory funnel); the water layer is extracted with diethyl ether (about 250 cc.) and the ether extract is added to the original ether layer. The combined ether solution is Washed twice with distilled water (about 100 cc. portions) and dried over anhydrous sodium sulfate (about 50 grams) for 30 minutes. The sodium sulfate is separated from the solution by filtration; the ether solution of hydrolysis products is added to a two liter Claisen flask; and an alkyd resin (550 grams of a short oil length soya modified glycerol phthalate alkyd resin, diluted to 55 weight per cent solids with xylene, prepared by the procedure hereinbefore described, using 3.32 mols of glycerol, 2.22 mols of soy bean oil and 3.08 mols of phthalic anhydride; the ingredients are reacted to an acid number of about 8.2, and the phthalic acid content of the finished resin is about 43 weight per cent; the oil length about 38 per cent) and Xylene (250 grams) are added to the flask. Ether is distilled from the flask until the temperature of the liquid rises to about 125 C.; the liquid is then transferred to a two liter three-necked flask fitted with a stirrer and a Stark and Dean trap equipped with a reflux condenser. The stirred liquid is then heated and maintained in gentle reflux for about three hours; during the refluxing xylene and water are distilled at such a rate that the amount of xylene removed amounts to about 200 cc., some water being removed with e.,as it is rec'ei ved f from themanufacturer; or it can be diluted with a' solvent so that the modifiedresin produced by a the xylene. A sample of tlie cooled resin (which is found to contain about "65" per cent by'weight of solids) is diluted with "Varnolene to about 50 weight per cent solids; this solution is then filmed onto a glass plate andfcured by heating in an electric oven for about one; hour at 200C. 1 to a light-colored, clear, glossy, hard, tough, flexible film. A film of the unmodified alkyd resin,

cured by heating in an electric oven for one hour at about 150 C., is soft, wrinkled, andbrown color; whereas'a film of a silicone modified alky' resin prepared as. described in the example, ve

cep-t thatthe dried other solution of the; hydrol sis products is diluted with xylene ,(250 grams)' f and. ethergdistilled until th-etliquid. temperature rises to about C. before the. alkyd resin is added to the solution. of "hydrolysis products;-v

cured by heating in an electric. oven for one. hour at about 200 C., is slightlyhazy.

Itis convenient to sample the mixture oithe, hydrolyzed silane solution and ;the alkyd. resin periodically during the heatingof this mixture, to.:film the sample. on a glass plate and torcure thefilm byheating it in an electric oven for 15 minutes at about 200 C I ,Such cured films tend to be hazy if prepared fr'om resin samplesjthat have been heated for only a shortperiod of time (e. g., as little as about one hour), butthis haziness gradually diminishes with continued heat ing; in many instances it is found that 'a waterclearjfilm results from curing a sample of a refsin that has been heated under gentle'refluxfor from paragraph of the example) heating is continued until the test indicates that the film cures waterclear.

When the method of the invention is used to produce an improved synthetic resin, the organosilane can be any of those hereinbefore described, and the amount of hydrolysis products of the organosilane that is added to the alkyd resin can be varied within wide limits; for example, the table shows the composition of several resins that can be prepared, using the procedure described in the second paragraph of the example. In the table, the compositions are entered on a weight per cent, solvent free basis; the alkyd resin used is that described in the second paragraph of the example; and the silane are considered to be completely hydrolyzed and condensed, i. e., it is considered that all hydrolyzable radicals attached to silicon atoms in silane molecules have been replaced by -OH radicals, and that condensation has occurred by reaction between each of these OH radicals and another -OI-I radical in the composition, with elimination of water, so that .each hydrolyzable radical has been replaced by an oxygen link, so that the average structure of the portion of the composition derived from the silane is represented by the empirical formula LSi(O)1-5 when the silicon in the resin is derived from a silane having three hydrolyzable radicals, L being used to designate an organic radical as hereinbefore described. The table, therefore, represents the compositions of the finished resins, on a solvent free basis.

'Ihemethod of the inventioncan be usedto produce' improved resins containing silicon regard:- les'sjofrthe ratio ofpsilicon' containing hydrolysis products tofalkyd-resin; but it is usually desir: able that' 'the; weight ratio of condensed hydrolysisproducts to alkyd resin be at least about and preferable that it be at 'least about 1:91. It ;usually, desirable that"the weightfratio of condensed hydrolysis products to alkydresinbe not greater than about-95 1, and preferable that it beinot' 'g'reater than about 4:1. A resin having too Iowa ratio of condensed hydrolysis products to falkyd'resin is not sufiiciently' improved to' jus f tif'yflthe expense of modification, while, a fresiri; having too high a ratio maylack homogeneity; or .beunreasonably expensive, V I

v I-Iawin'g) described. the invention, I claim:

1. A'method of producing synthetic c-resins that; comprises i hydrolyzing a silane whose molecule consists of a silicon atom to which are attached four nonovalentradicals from one to vtwo of which are organic .-radicals attached throughja CQIbOIly-tO-Si-HCOI]. linkage, cand the remainder: of whichare hydrolyzable radicals, in the presence of :an vorganic solvent in a volume equal toat: least rone half-the, volume of the silane, said ore-v ganicfisolventEbeing :one which forms a -two'- phase-system :with water, adding the resulting; solution l of the hydrolyzed product, comprising theoriginal organic solvent in'a volume equal to at --1ea st halfithe. originalljiqolume of the silane, to angor anicrsolvent solutioncjofanralkyd resin, a djf while distilling,to remove, wate guntil va a i no. cured, in of. the product is free: from haze.

2.:IA method: f producing: synt etic" resins" as. claimed in claim 1 in which the 'distillationr -j. moves lithe original fuorganic ;.v.so1\ r.ent., as wellgflsi;

water. Y

3. A method. of nroducing synthetic resins. as claimed in, claim- 2 inwhich the. organic solvent; is a dialkyl ether having?from I4 --to v,6 carbon atome.

f 4. A method of: pro ucing. synthetic resinsj as: claimedin' claim 3 in which the organicisolyent is .diethylethen a 5.}A method of producingsynthetic iresins claimedin claim 1 in which the. step of hydrolyz ingthesilaneis carried out' .by Qbrin'gingJa hy-g, drolyzirig solution intovcontact with a solution .of j

the silaneiri the: organiq solyent,

"RAYMOND ,HL B N E EnE bEsfoIT D.

The followingkreferences are of -record in the file of this patent :1- I

' UNITED STATES PATENTS OTHER REFERENCES 1 Gardner Physical and Chemical Examination of Paints, Varnishes, Lacquers and Colors; 10th edition, 1946 (Gardner Laboratories); 478,;

479 and 48%. Copy in Divl 50f", 

1. A METHOD OF PRODUCING SYNTHETIC RESINS THAT COMPRISES HYDROLYZING A SILANE WHOSE MOLECULE CONSISTS OF A SILICON ATOM TO WHICH ARE ATTACHED FOUR MONOVALENT RADICALS, FROM ONE TO TWO OF WHICH ARE ORGANIC RADIALS ATTACHED THROUGH A CARBON-TO-SILICON LINKAGE, AND THE REMAINDER OF WHICH ARE HYDROLYZABLE RADICALS, IN THE PRESENCE OF AN ORGANIC SOLVENT IN A VOLUME EQUAL TO AT LEAST ONE-HALF THE VOLUME OF THE SILANE, SAID ORGANIC SOLVENT BEING ONE WHICH FORMS A TWOPHASE SYSTEM WITH WATER, ADDING THE RESULTING SOLUTION OF THE HYDROLYZED PRODUCT, COMPRISING THE ORIGINAL ORGANIC SOLVENT IN A VOLUME EQUAL TO AT LEAST HALF THE ORIGINAL VOLUME OF THE SILANE, TO AN ORGANIC SOLVENT SOLUTION OF AN ALKYD RESIN, AND HEATING WHILE, DISTILLING TO REMOVE WATER UNTIL A CURED FILM OF THE PRODUCT IS FREE FROM HAZE. 